Automated tow/tape placement system

ABSTRACT

Systems, methods, and devices of the various embodiments may provide Automated Tape (or Tow) Placement (ATP) systems including machine-based parts that support prepreg tape laying processes to build composite parts. Various embodiments may be applied to materials that may be consolidated during fabrication and/or may be used to fabricate parts that may require post processing steps.

CROSS-REFERENCE TO RELATED PATENT APPLICATION(S)

This patent application is a continuation-in-part of U.S. patentapplication Ser. No. 17/369,109 filed on Jul. 7, 2021, the contents ofwhich are hereby incorporated by reference in its entirety.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

The invention described herein was made by an employee of the UnitedStates Government and may be manufactured and used by or for theGovernment of the United States of America for governmental purposeswithout the payment of any royalties thereon or therefore.

BACKGROUND OF THE INVENTION

Automated Tape (or Tow) Placement (ATP) has seen adoption in industrysectors, such as aerospace, transportation, energy, etc., that usecomposite structures and parts. ATP manufacturing is a method ofconstructing composite structures by using robotic automation to placestrips of prepreg (e.g., carbon fiber prepreg, etc.), commonly referredto as tows or tapes, onto a tooling surface. One or more tows are oftenspool fed into an applicator head (also referred to as a depositinghead) of an ATP system. When more than one tow is used, the tows arelined up in a row side-by-side to be placed onto the tooling surface. Asingle tow being deposited or an arrangement of side-by-side tows isoften called a course, and a course is placed on the tooling surface onecourse at a time. Multiple courses placed side-by-side make up a ply,and plies are deposited on top of each other to make the part.

Current ATP systems often include a tape laying applicator head systemthat lays prepreg tape or tow by translating on a robot arm or gantryabove a tooling surface. The standard applicator heads have severalcommon parts including: 1) a heating system that develops prepreg tack(e.g., stickiness) and drape (e.g., pliability) just prior to bonding(e.g., adhering) to the substrate layer; 2) a compaction drive wheelthat applies a predetermined amount of pressure to the tape to assistbonding; 3) a system to cut and feed tape through the applicator head;and 4) a positioning system to translate and position the applicatorhead to directionally lay the tape to build the composite part. Thesestandard systems often involve obtuse angle head rotation in scenariosin which plies are to be adjacently placed in a bidirectional mannerneeded to increase the width of the part beyond the width of the tape.Obtuse angle head rotation can be important for production speed,otherwise without obtuse angle head rotation, the applicator head musttranslate across the build to a new starting point, without placing anytape, consuming time with each placed layer. Whether using obtuse anglehead rotation or translation across the build, both methods reduceplacement accuracy due to inherent additive error effects of mechanicalmotion, or require additional position checks to mitigate the additiveeffects of location error.

Additionally, these current ATP systems require a manufactured toolsurface to build up the part. The tool surface serves severalpurposes: 1) as a surface to apply pressure against; 2) to help developand keep the shape of the part's surface; and 3) to assist in curing thefinished part under pressure in an autoclave, oven, or press.Additionally, a tensioning system is required in current ATP systems sothat the tape is placed in a controlled manner without uncontrolled feedout. The tensioning system may be located on the applicator head, or aftof the applicator head, as part of the tape spooling arrangement.

Other current ATP systems often include applicator heads that aredesigned to feed tape from several prepreg reels or spools so thatvarying widths of tape can be laid down simultaneously. This has theadded advantage of laying tape in an angular fashion, minimizing wasteat the starting and endpoints, or to produce a flat surface curve withminimal ply wrinkling as the outside edge requires more tape than theinside edge. These current ATP systems are used with thermosetting andthermoplastic tapes. The applicator heads for both these types ofcurrent ATP systems differ only in scenarios in which the prepreg tapehas release paper that has to be removed during layup, typical ofthermosetting prepreg, requiring an additional peel off and wind-upsystem on the applicator head.

While current ATP systems have seen adoption by industry, currentrobotic technology is based on different use cases, such aspick-and-place, automated welding, and fastener insert technology forautomated assembly, and is not optimized composite layup technologyneeds. Composite layup technology would generally benefit from roboticsystems that provided multi-axis dexterity, robotic arm movement toposition the applicator head, and precision location controls. Compositelayup technology would uniquely benefit from robotic systems that enablethe part under construction to translate instead of the robotic armmoving the applicator head, that support start and stop of layup, thatinclude a division of tasks among at least two robots working inconcert, that provide real-time chemical and physical analysis of thepart during build, and that enable in-situ repair of the part.Additionally, current ATP systems require tooling of the robots to layupcomposites which can present problems.

Additionally, current ATP systems that include tape laying roboticsystems are unidirectional in tape placement. In scenarios in whichbidirectionality is required, the complete head system must rotate andtraverse, unless a direct overlay is being done, which adds undesiredcomplexity to the part fabrication process. Additionally, in current ATPsystems prepreg/tape spools are installed by hand and not in anauto-insert-feed-removal system which would be more beneficial.Additionally, current ATP systems the part doesn't translate duringbuild and therefore the part cannot be built beyond a tool or frame sizefor the ATP system.

BRIEF SUMMARY OF THE INVENTION

Methods and devices of the various embodiments may provide AutomatedTape (or Tow) Placement (ATP) systems including machine-based parts thatsupport prepreg tape laying processes to build composite parts. Variousembodiments may be applied to materials that may be consolidated duringfabrication and/or may be used to fabricate parts that may require postprocessing steps.

Various embodiments may include an ATP head, comprising: a layup truck,comprising: two rollers; and a rotating transmission supporting the tworollers, wherein the rotating transmission is configured to tilt suchthat in a first position of the rotating transmission a first of the tworollers operates as a compaction drive wheel and the second of the tworollers operates as a tensioning guide drive wheel for a tape beingdeposited by the ATP head and in a second position of the rotatingtransmission the second of the two rollers operates as the compactiondrive wheel and the first of the two rollers operates as the tensioningguide drive wheel for the tape being deposited by the ATP head.

Various embodiments may include an ATP system, comprising: a first ATPhead, comprising: a first layup truck, comprising: two rollers; and arotating transmission supporting the two rollers, wherein the rotatingtransmission is configured to tilt such that in a first position of therotating transmission a first of the two rollers operates as acompaction drive wheel and the second of the two rollers operates as atensioning guide drive wheel for a first tape being deposited by thefirst ATP head and in a second position of the rotating transmission thesecond of the two rollers operates as the compaction drive wheel and thefirst of the two rollers operates as the tensioning guide drive wheelfor the first tape being deposited by the first ATP head.

Embodiments may include an ATP head for deposition of a prepreg tape,where the head includes a layup truck according to the present approach.The layup truck may comprise at least one stanchion, two rollers, arotating transmission pivotally mounted to the at least one stanchion,where the transmission has at least two support arms rotatablysupporting the two rollers so that the two rollers are configured torotate about a first axis (e.g., a Y-axis). The rotating transmissionmay be configured to tilt about the first axis relative to the at leastone stanchion. In such tilt, a first of the at least two support armsmay move away along a second axis from tape deposition, where the secondaxis is orthogonal to the first axis, and a second of the at least twosupport arms may move along the second axis toward tape deposition.Thus, in a first position of the rotating transmission a first of thetwo rollers operates as a compaction drive wheel and the second of thetwo rollers operates as a tensioning guide drive wheel for a tape beingdeposited by the ATP head, and in a second position of the rotatingtransmission, the second of the at least two support arms is moving awayalong a second axis from tape deposition and the first of the at leasttwo support arms moving along the second axis toward tape deposition,the second of the two rollers operates as the compaction drive wheel andthe first of the two rollers operates as the tensioning guide drivewheel for the tape being deposited by the ATP head. The tape beingdeposited by the ATP head in such embodiments passes between the tworollers, and the tape being deposited by the ATP head contacts both ofthe two rollers in both of the first position of the rotatingtransmission and the second position of the rotating transmission. Asthe transmission tilts, the two rollers rotate about each other in aplane defined by the first and second axes (e.g., a vertical plane) sothat the two rollers are in engagement with the tape facilitating achange in laydown direction while maintaining tension on the tape. Thetwo rollers may be in constant engagement, so as maintain asubstantially consistent or constant tension, as may be desired for theprepreg tape.

These and other features, advantages, and objects of the presentinvention will be further understood and appreciated by those skilled inthe art by reference to the following specification, claims, andappended drawings.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIG. 1A is a block diagram of an example layup truck including twinrollers in accordance with various embodiments.

FIG. 1B is a block diagram of the example layup truck of FIG. 1A and anactuator illustrated in accordance with various embodiments.

FIG. 2 is a block diagram of an example layup truck illustrating truckcycle tilt in response to a change in direction of an Automated Tape (orTow) Placement (ATP) head in accordance with various embodiments.

FIG. 3 a block diagram of an example layup truck illustrating howprepreg tape is fed through the layup truck.

FIG. 4A is a block diagram of an example layup truck and othercomponents of an ATP head illustrating tape placement in a firstdirection in accordance with various embodiments.

FIG. 4B is a block diagram of the example layup truck and the othercomponents of the ATP head of FIG. 4A illustrating tape placement in asecond direction in accordance with various embodiments.

FIG. 5 is a block diagram of two example layup trucks and the othercomponents of a dual ATP head ATP system illustrating tape placement inaccordance with various embodiments.

FIG. 6 illustrates a comparison of different ATP head layup movementsrequired to build a unidirectional panel.

FIG. 7A is a block diagram of an example single ATP head ATP systemaccording to various embodiments.

FIG. 7B is a block diagram of an example dual ATP head ATP systemaccording to various embodiments.

FIG. 8A is a block diagram of an example grip truck including twinrollers in accordance with various embodiments.

FIG. 8B is a block diagram of the example grip truck of FIG. 8A and anactuator illustrated in accordance with various embodiments.

FIG. 9 is a block diagram of two example grip trucks of a dual ATP headATP system during tape laying in accordance with various embodiments.

FIG. 10 is a block diagram of components of an example dual ATP head ATPsystem illustrating tape placement in accordance with variousembodiments.

FIG. 11 is a block diagram of an example ATP head in accordance withvarious embodiments.

FIG. 12 is a block diagram of a portion of an example ATP system duringtape lay down in accordance with various embodiments.

FIG. 13 is a component block diagram of a laptop that is a computingdevice suitable for use in the various embodiments.

DETAILED DESCRIPTION OF THE INVENTION

For purposes of description herein, the terms “upper,” “up,”, “down,”“top,” “bottom,” “lower,” “right,” “left,” “rear,” “front,” “vertical,”“horizontal,” and derivatives thereof shall generally relate to theinvention as oriented in FIG. 10 . However, it is to be understood thatthe invention may assume various alternative orientations and stepsequences, except where expressly specified to the contrary. It is alsoto be understood that the specific devices and processes illustrated inthe attached drawings, and described in the following specification, aresimply exemplary embodiments of the inventive concepts defined in theappended claims. Hence, specific dimensions and other physicalcharacteristics relating to the embodiments disclosed herein are not tobe considered as limiting, unless the claims expressly state otherwise.

The word “exemplary” is used herein to mean “serving as an example,instance, or illustration.” Any implementation described herein as“exemplary” is not necessarily to be construed as preferred oradvantageous over other implementations.

The various embodiments will be described in detail with reference tothe accompanying drawings. Wherever possible, the same reference numberswill be used throughout the drawings to refer to the same or like parts.References made to particular examples and implementations are forillustrative purposes and are not intended to limit the scope of theinvention or the claims.

The term “computing device” as used herein refers to any one or all ofcellular telephones, smartphones, personal or mobile multi-mediaplayers, personal data assistants (PDA's), laptop computers, personalcomputers, servers, tablet computers, smartbooks, ultrabooks, palm-topcomputers, multimedia Internet enabled cellular telephones, and similarelectronic devices that include a memory and a programmable processor.While specific examples are listed above, a computing device asdiscussed herein may include any electronic device that includes aprocessor and executes application programs.

While Automated Tape (or Tow) Placement (ATP) has seen adoption inindustry sectors, such as aerospace, transportation, energy, etc., thatuse composite structures and parts, current robotic technology is basedon different use cases, such as pick-and-place, automated welding, andfastener insert technology for automated assembly, and does not meet allATP system needs.

One approach to addressing the shortcomings in current ATP systems hasbeen a dual robot system disclosed by General Atomics AeronauticalSystems, Inc. in U.S. Patent Application Publication No. 2018/0257305.This so called “tool-less” system for fabrication of thermoplasticcomposites (TPCs) uses two robots that work in concert against eachother. One robot dispenses and preheats the thermoplastic prepreg tape,and uses its compaction roller to apply pressure to the roller of theopposing robot. This creates a virtual tool surface and both robotsoperate in concert using a computer aided design/computer aidedmanufacturing (CAD/CAM) program. This virtual tool eliminates the needfor a solid tool, and the use of thermoplastics mitigates the need forautoclave or hot press post processing, as the composite is consolidatedin-situ during the build. Additionally, this also allows for asymmetricbuilding of composite parts (i.e., features can be independently addedto each face of the composite panel), and complex out-of-plane curvaturethat is difficult and costly with a standard solid-faced tool. However,this General Atomics Aeronautical Systems, Inc. system is not in factentirely tool-less as it requires a starting frame for the initialanchoring of the prepreg to start the structural build. As such, thisGeneral Atomics Aeronautical Systems, Inc. system does not meet allcomposite layup technology needs, for example because it requires astarting frame for the initial anchoring of the prepreg to start thestructural build.

Various embodiments provide ATP systems that address the shortcomings ofcurrent ATP systems and/or the shortcomings of the General AtomicsAeronautical Systems, Inc. system discussed above, and representimprovements to composite layup technology by mitigating severalproblems faced in current ATP systems and/or the General AtomicsAeronautical Systems, Inc. system discussed above.

Methods and devices of the various embodiments may provide ATP systemsincluding machine-based parts that support prepreg tape laying processesto build composite parts. Various embodiments may be applied tomaterials that may be consolidated during fabrication and/or may be usedto fabricate parts that may require post processing steps.

Systems, methods, and devices of the various embodiments may avoidobtuse head rotation or cross-tool translation when laying adjunct tapeplies, the various embodiments may support using at least two robots tosimultaneously place tape on both sides of a part, the variousembodiments may eliminate a need of an external anchoring frame, and/orthe various embodiments may provide the ability to partially, or fully,translate the part during build in addition to translating theapplicator head. Various embodiments may increase layup speed incomparison to current ATP systems by reduction of head rotation reversalduring bidirectional tape layup, and simultaneous tape placement onopposite sides. Various embodiments may increase placement accuracy incomparison to current ATP systems through decreased movement betweentape layup resulting in decrease tape misalignment, and elimination ofan anchoring frame through simultaneous pressure extrusion of prepregusing at least two robots. The use of at least two robots tosimultaneously place tape on both sides of a part may eliminate the needfor a tool or frame and may remove the boundary of part size by havingthe part translate during build, rather than the ATP heads. In variousembodiments, the method used to translate the part may differ dependingon the weight (not mass) of the part, the part's stiffness, the geometryof the part, and a center of gravity of the part during the build.

Various embodiments may provide a layup roller head-based ATP head foran ATP system. In various embodiments, the ATP head may include a layuptruck having twin rollers. The layup truck may tilt such that a first ofthe rollers of the layup truck may operate as a tensioning guide drivewheel for a prepreg tape being deposited by the ATP head in a firstdirection and the second of the rollers of the layup truck may operateas a compaction drive wheel for the prepreg tape being deposited by theATP head in the first direction. The ATP head may be bidirectional inthat when the ATP head proceeds in a second direction opposite to thefirst direction the layup truck may tilt such that that the second ofthe rollers of the layup truck may operate as the tensioning guide drivewheel for the prepreg tape being deposited by the ATP head in the seconddirection and the first of the rollers of the layup truck may operate asthe compaction drive wheel for the prepreg tape being deposited by theATP head in the second direction. Said another way, the roles of thetwin rollers, i.e., as tensioning guide wheel or compaction drive wheel,may switch via the tilt of the layup truck as the ATP head changesdirection.

FIGS. 1A-5 illustrate aspects of example layup trucks including twinrollers in accordance with various embodiments, with orthogonal X-axis,Y-axis, and Z-axis as shown for reference. FIG. 1A is a block diagram ofa layup truck 100 including twin rollers 103, 104 shown oriented torotate along the Y-axis in accordance with various embodiments. Thelayup truck 100 may be a component of an ATP head in various embodimentsas discussed herein. FIG. 1B is a block diagram of the layup truck 100and an actuator 111 illustrated in accordance with various embodiments.FIG. 2 is a block diagram side view (i.e., along Y-axis) of the layuptruck 100 illustrating truck cycle tilt about the Y-axis in response toa change in direction of an ATP head in accordance with variousembodiments. FIG. 3 a block diagram of the layup truck 100 illustratinghow prepreg tape 101 is fed through the layup truck 100. FIG. 4A is ablock diagram of the layup truck 100 and other components of an ATP headillustrating tape 101 placement in a first direction D1 in accordancewith various embodiments. FIG. 4B is a block diagram of the layup truck100 and the other components of the ATP head illustrating tape 101placement in a second direction D2, opposite the first direction D1, inaccordance with various embodiments. FIG. 5 is a block diagram of twoexample layup trucks 100 and the other components of a dual ATP head ATPsystem illustrating tape 101 placement in accordance with variousembodiments.

With reference to FIGS. 1A-5 , the layup truck 100 may include twinrollers 103, 104 supported relative to one another between two sides ofa wheel truck rotating transmission 109. The rollers 103, 104 may becomprised of any suitable material, such as thermoplastics, metals,etc., and may rotate around their central axes (i.e., their Y-axes inFIG. 1A) in both clockwise and counterclockwise directions. The wheeltruck rotating transmission 109 may take various forms. However,transmission 109 may include a rotatable support, bearing, sleeve, orcoupling by which transmission 109 may be mounted to stanchions 110 oflayup truck 100; in this configuration, transmission 109 may rotateabout the Y-axis relative to stanchions 110 so as to effect theconfiguration shown as the truck cycle tilt in FIG. 2 ; the tiltingbetween a first and second position show rollers 103 and 104 exchangingrelative positioning to prepreg tape 101 along the Z-axis. As thetransmission 109 tilts, the two rollers 103, 104 rotate about each otherin a vertical plane (i.e., the X-Z plane as shown) so that the tworollers 103, 104 are able to be in constant engagement with the tape101; in this way, the tilt facilitates a change in laydown directionwhile maintaining substantially constant or consistent tension on tape101. “Substantial” in this sense of tension during truck cycle tiltingmeans relatively and acceptably consistent tension desired for tape 101when the desired truck cycle tilt has been achieved.

As illustrated in one example, opposite sides of the wheel truckrotating transmission 109 may include or define support arms 181 (see,e.g., FIG. 8A) supporting the rollers 103, 104 in rotatable mannertherebetween, such that the rollers 103, 104 may rotate between thesupport arms 181, and each support arm 181 may be connected to itscenter to its own respective rotating bearing 180 of transmission 109such that the support arms 181, and the rollers 103, 104 supportedtherein, may pivot around the axis of rotation of the two rotatingbearings 180 (i.e., shown as the Y-axis.) The wheel truck rotatingtransmission 109 may pivot around their central axes (i.e., the Y-axisin FIGS. 1A, 8A, and 8B) in both clockwise and counterclockwisedirections. The rollers 103, 104 may rotate opposite one another duringoperation of the layup truck 100. The wheel truck rotating transmission109 may be supported by stanchions 110. The wheel truck rotatingtransmission 109 may be configured to hold the rollers 103, 104 inselected positions, such as in one position with the roller 103 extendedtoward the surface on which the tape 101 is being laid and the roller104 held back (i.e., along the Z-axis) from the surface on which thetape 101 is being laid (e.g., as shown in FIG. 4B) and another positionwith the roller 104 extended toward the surface on which the tape 101 isbeing laid and the roller 103 held back from the surface on which thetape 101 is being laid (e.g., as shown in FIG. 4A).

The wheel truck transmission 109 may be configured to switch betweenselected positions by being controlled to pivot around their centralaxes (i.e., their Y-axes in FIG. 1A) in the clockwise and/orcounterclockwise directions. The pivoting of the wheel truck rotatingtransmission 109 may be controlled by a processor (or other typecontroller) of the ATP head including the layup truck 100 and thecontrol of the pivoting of the wheel truck rotating transmission 109 maythereby control which roller 103, 104 is operating as a compaction drivewheel and which roller 103, 104 is operating as a tensioning guide drivewheel. In some embodiments, mechanical actuators 111 may be coupled tothe stanchions 110 of the layup truck 100 and configured to translatethe layup truck 100 back and forth along the Z-axis direction. Theactuators 111 may be any type of actuators, such magnetically operatedactuators (e.g., solenoids, etc.), electrically operated actuators(e.g., piezoelectric stacks, electric motor driven ball screw actuators,etc.), hydraulic pump operated actuators (e.g., pistons, etc.), pressurepump operated actuators (e.g., pistons, diaphragms, etc.), and/ormechanical actuators (e.g., springs, etc.). The actuators 111 may becontrolled by a processor (or other type controller) of the ATP headincluding the layup truck 100. The stanchion 110 controls therelationship of the layup truck 100 to the composite part, with thepressure actuator 111 serving to consolidate the tape 101 to a substrateor support structure (e.g., tool 107) or opposing tape being depositedby another ATP head (e.g., as seen in FIG. 5 ). The rollers 103, 104 mayalways rotate opposite to one another, but in the same directionpreventing prepreg tape 101 wrinkling/binding and allowing for aconsistent even movement and tape 101 tension through parts of the ATPmachinery, thereby simplifying continuous operation. The roller 103, 104operation also decreases the amount of movement required forbidirectional tape 101 layup as the ATP head is not required to bothrotate and translate, or translate back down the part and to the side tolay the next adjacent layer, minimizing mechanically induced translationerrors and dwell time in comparison to non-dual roller head systems. TheATP head of the various embodiments including the layup truck 100 mayshift the width of the tape 101, and the rotation is translated to thetilt oscillation of the layup truck 100 via the wheel truck rotatingtransmission 109. This tilting may be especially beneficial when thebuild is complete (e.g., the tape 101 is cut by a tape cutter 102) orthe tape 101 runs out and new tape 101 is auto-fed into the system alongthe same pathway in the same direction as the previously tape 101.

The layup truck 100 may eliminate obtuse head rotation and/or cross-tooltranslation when laying adjunct tape plies as the rollers 103 and 104may operate as an adjustable pinch and compaction roller system. FIG. 2demonstrates the layup truck 100 movement versus the movement directionof the tape 101 in scenarios in which the ATP head including the layuptruck 100 may not be translating but the part being built may betranslating. Specifically, the actuators 111 may move the layup truck100 in the M direction and the layup truck 100 may cycle tilt around theY-axis as the ATP head changes lay down direction from a first directionD1 to an opposite second direction D2. The roller 103, 104 in contactwith the laid down tape 101 may change as the direction changes (i.e.,with respect to the Z-axis.) For example, when the ATP head is moving indirection D1, the roller 104 may contact the tape 101 and operation as acompaction drive wheel while the roller 103 operates as a tensioningguide drive wheel. When the ATP head is moving in direction D2, theroller 103 may contact the tape 101 and operation as a compaction drivewheel while the roller 104 operates as a tensioning guide drive wheel.FIG. 3 illustrates how the tape 101 is fed through the layup truck 100.The tape 101 may be held of a prepreg tape reel (or spool) and proceedin between the two rollers 103, 104. FIG. 3 illustrates the view of thetape 101 in a scenario in which the roller 104 may be operating as acompaction drive wheel while the roller 103 is operating as a tensioningguide drive wheel.

Thus, transmission 109 may have at least two support arms 181 (FIG. 8A)rotatably supporting the two rollers 103, 104 so that the two rollersare configured to rotate about a first axis (e.g., a Y-axis). Therotating transmission 109 may be configured to tilt about the first axisrelative to the at least one stanchion 110. In such tilt, a first of theat least two support arms 181 may move away along a second axis (Z-axis)from tape 101 deposition, where the second axis is orthogonal to thefirst axis, and a second of the at least two support arms 181 may movealong the second axis toward tape 101 deposition. Thus, in a firstposition of the rotating transmission 109 a first of the two rollers103, 104 operates as a compaction drive wheel and the second of the tworollers 103, 104 operates as a tensioning guide drive wheel for a tape101 being deposited by the ATP head 100, and in a second position of therotating transmission 109, the second of the at least two support arms181 is moving away along a second axis from tape 101 deposition and thefirst of the at least two support arms 181 moving along the second axistoward tape 101 deposition, the second of the two rollers 103, 104operates as the compaction drive wheel and the first of the two rollers103, 104 operates as the tensioning guide drive wheel for the tape 101being deposited by the ATP head 100. The tape 101 being deposited by theATP head 100 in such embodiments passes between the two rollers 103,104, and the tape 101 being deposited by the ATP head 100 contacts bothof the two rollers 103, 104 in both of the first position of therotating transmission 109 and the second position of the rotatingtransmission 109. As the transmission tilts, the two rollers 103, 104rotate about each other in a plane defined by the first and second axes(e.g., the X-Z plane as shown) so that the two rollers 103, 104 are inengagement with the tape 101 facilitating a change in laydown directionwhile maintaining tension on the tape 101. The two rollers 103, 104 maybe in constant engagement, so as maintain a substantially consistent orconstant tension, as may be desired for the prepreg tape 101.

FIGS. 4A and 4B illustrate the layup truck 100 along with othercomponents of an ATP head, such as heat applicators 105 and tape cutters102. The heat applicators 105 may be any type heat applicators, such aslamps, resistive heaters, lasers, etc. When turned on, the heatapplicators 105 may apply heat 106 to the tape 101 being deposited. Tapecutters 102 may be any type cutters configured to cut the tape 101, suchas mechanical blades, lasers, etc. In various embodiments, a heatapplicator 105 and tape cutter 102 may be disposed on both sides of thelayup truck 100 to heat and/or cut the tape 101 in the respectivedirection the tape 101 is being laid down. The heated and consolidatedtape 101 exiting the ATP head may form the consolidated composite buildform (or part) 108. While only single heaters 105 are shown turned in onvarious figures, both heaters 105 may be turned on together with oneheater operating as a pre-heater and one acting as a head heater at agiven time. The directional movement of the ATP head and the tiltcycling of the layup truck 100 is further detailed in FIGS. 4A and 4B.FIGS. 4A and 4B illustrate the operations of a single layup truck 100 ina single ATP head ATP system where the single ATP head isbidirectionally placing tape 101 in opposite directions as the tool 107(or part) is translated, specifically X direction D1 in FIG. 4A and theopposite X direction D2 in FIG. 4B. The tape 101 is fed between therollers 103, 104 in the Z direction F1.

Similarly, in FIG. 5 , a two ATP head system is shown in which two layuptrucks 100 are shown preforming a frameless build without a tool, i.e.,without the need for the tool 107. The system illustrated in FIG. 5 canbuild from one or both sides of the composite 108 once the initial layeris present. In FIG. 5 , tape 101 may be fed in the Z-axis direction F1to a first layup truck 100 and in the Z-axis direction F2 to a secondlayup truck 100. The rollers 104 operating as compaction drive wheelsmay exert forces on the tapes 101 therebetween and thereby the tapes 101may exert opposite forces on one another. FIG. 5 illustrates that theheaters 105 opposite the rollers 104 may apply heat to the tapes 101 toenable the adjoining sides of the tapes 101 to fuse together at contact.By comparing FIG. 5 with FIG. 2 , which includes the addition of thepressure actuator 111, the capability of direction reversal required foradjacent tape 101 layup becomes apparent.

FIG. 6 illustrates a comparison of different ATP head layup movementsrequired to build a unidirectional panel. FIG. 6 compares threedifferent head lay down schemes, 600, 610, and 620. Lay down scheme 600is a lay down scheme enabled by the dual roller head of the variousembodiments, such as an ATP head including a layup truck 100. Lay downschemes 610 and 620 are lay down schemes used by ATP systems withoutdual roller heads. Tape laying is illustrated by solid path arrows inFIG. 6 and head translation is illustrated by broken path arrows in FIG.6 . Portion 601 of scheme 600 shows that a tape lay down in a firstdirection 602 is followed by a sideways head translation 603, and a tapelay down in a second direction 604 opposite to the first direction 602.No head rotation or diagonal head translation is required in scheme 600due to the operations of the dual roller head of the variousembodiments, such as an ATP head including a layup truck 100. Theadvantages of decreasing the total steps required for standardapplicator heads are shown in the defined layup paths detailed in FIG. 6. In comparison, scheme 610 requires head rotation as illustrated in theportion 611 of the scheme 610 showing that head rotation 612 occursafter the lay down in the first direction 602 while the head translation603 is occurring. Thus, the scheme 610 requires at least one additionalhead rotation step 612 for each portion 611 that is not required in theportions 601 of scheme 600. As another comparison, scheme 620 requiresoff axis translation (i.e., diagonal translation 622) as illustrated inthe portion 621 of the scheme 620 showing that diagonal translation 622occurs after each lay down. A head rotation step 612 is also required.Thus, the scheme 620 requires at least one additional head rotation step612 and diagonal translation 622 for each portion 621 that is notrequired in the portions 601 of scheme 600.

FIG. 7A is a block diagram of an example single ATP head 706 ATP system700 according to various embodiments including a layup truck 100. Theillustration of the ATP system 700 in FIG. 7A is a simplified version ofan ATP system, and one of ordinary skill in the art will understand anATP system suitable for use with various embodiments may include more orless components than shown in FIG. 7A and may operate differently thanthe ATP system 700 illustrated in FIG. 7A.

In general, the ATP system 700 may include an ATP head 706 that receivesat least one tow (or tow tape) 101 that is deposited and compacted ontoa tool 107 (e.g., a substrate or other form) to form a laid-down course108. The tool 107 may operate as a mold for a part to be built up by therepeated depositing of laid-down courses 108 by the ATP head 706. Whileillustrated and discussed as a single tow 101 system, multiple tows ortapes may be feed and deposited by the ATP head 706 and multiple tapesmay be substituted for the single tape 101 in the various embodiments.In some configurations, the ATP head 706 may be stationary and the tool107 may be supported on an optional moving support 703 (e.g., atranslatable platform, rotating spindle, etc.). In some configurations,the ATP head 706 may be mounted on a moving system, such as an optionalrobotic arm 702 and/or optional gantry system 701, and translaterelative to the tool 107 that remains stationary. In someconfigurations, the ATP head 706 may be mounted on a moving system, suchas an optional robotic arm 702 and/or optional gantry system 701, andtranslate relative to the tool 107 and the tool 107 may be supported onan optional moving support 703 (e.g., a translatable platform, rotatingspindle, etc.) such that both the ATP head 706 and the tool 107 may moverelative to one another.

In operation, tape 101 may be feed from reel (or spool) 709 (or multiplespools in a multiple tape system). While illustrated as within the ATPhead 706, the reel 709 may be located outside the ATP head 706. The tow(or tow tape) 101 may be a fiber tape strip, such as epoxy fiber tapestrip, carbon fiber tape strip, carbon fiber epoxy tape strip, etc. Thetape 101 may feed through the rollers 103, 104 of the layup truck 100and be heated and/or cut by the heat applicators 105 and/or tape cutters102. In various embodiments, the tape 101 from the reel 709 may beauto-fed by the ATP head 706 from the reel 709 through the rollers 103,104 of the layup truck 100.

As illustrated in FIG. 7A, the ATP system 700 may include a controller707, such as a processor, microcontroller, etc., configured to controlthe operations of the layup truck 100, actuators 111, and/or componentsof the ATP head 706, such as the heat applicators 105, cutters 102, tapereels 709, etc. The ATP head 706 may include sensors (e.g., positionsensors, condition sensors, status sensors, etc.) to provide data (e.g.,position data, condition data, status data, etc.) of the layup truck100, actuators 111, and/or components of the ATP head 706, such as theheat applicators 105, cutters 102, tape reels 709, etc., to thecontroller 707. The controller 707 may be configured to determinepositions, conditions, statuses, etc., of the layup truck 100, actuators111, and/or components of the ATP head 706, such as the heat applicators105, cutters 102, tape reels 709, etc. The controller 707 may beconnected to a computing device 705 of the ATP system 700, such as viaone or more wired and/or wireless connections. The computing device 705may be configured to control the operations of the controller 707, layuptruck 100, actuators 111, and/or components of the ATP head 706, such asthe heat applicators 105, cutters 102, tape reels 709, etc. As aspecific example, the computing device 705 may be configured to controlthe layup movements of the ATP head 706 and operation of the layup truck100 and/or actuators 111 in accordance with various embodiments tobidirectionally lay down prepreg tape 101 to build a composite part. Asa further specific example, the computing device 705 may be configuredto control the layup movements of the ATP head 706 and operation of thelayup truck 100 and/or actuators 111 in accordance with variousembodiments to bidirectionally lay down prepreg tape 101 to build acomposite part according to a lay down scheme, such as lay down scheme600. The lay down scheme, such as lay down scheme 600, may be configuredsuch that no head rotation of the ATP head 706 and/or diagonal headtranslation of the ATP head 706 may be required to build a compositepart.

FIG. 7B is a block diagram of an example dual ATP head 706 ATP system750 according to various embodiments. Each ATP head 706 of the ATPsystem 750 may be similar to the ATP head 706 of the ATP system 700described above. The dual ATP head 706 ATP system 750 may be similar tosystem 700 of FIG. 7A, except that the two ATP heads 706 may interactwith one another to deposit their respective tapes 101 without the needfor a tool 107 or moving support 703. In the ATP system 750, both ATPheads 706 may be controlled by the computing device 705. As a specificexample, the computing device 705 may be configured to control the layupmovements of both of the ATP heads 706 and operation of their respectivelayup trucks 100 and/or actuators 111 in accordance with variousembodiments to bidirectionally lay down prepreg tape 101 between the twoATP heads 706 to build a composite part. As a further specific example,the computing device 705 may be configured to control the layupmovements of the ATP heads 706 and operation of their respective layuptrucks 100 and/or actuators 111 in accordance with various embodimentsto bidirectionally lay down prepreg tape 101 to build a composite partaccording to a lay down scheme, such as lay down scheme 600. The two ATPheads 706 may be controlled by the computing device 705 in concert withone another such that the two ATP heads 706 apply opposite force to eachother's dispensed tape 101 along the lay down paths of the lay downscheme, such as lay down scheme 600, thereby enabling tool-less (e.g.,without the need for the tool 107 or moving support 703) build-up of apart. The lay down scheme, such as lay down scheme 600, may beconfigured such that no head rotation of the ATP heads 706 and/ordiagonal head translation of the ATP heads 706 may be required to builda composite part.

Various embodiments may include a handling attachment for compositebuilds. In various embodiments, the handling attachment for compositebuilds may be a grip truck including at least one grip truck roller,such as one, two, or more rollers, configured to press, hold, andtranslate the composite build (i.e., the part being built by the ATPsystem). FIGS. 8A-9 illustrate features of an example grip truck 800including twin rollers 103, 104 that may simultaneously press, hold, andtranslate the composite build (i.e., the part being built by the ATPsystem). FIG. 8A is a block diagram of an example grip truck 800including twin rollers 103, 104 in accordance with various embodiments.FIG. 8B is a block diagram of the example grip truck 800 and an actuator811 illustrated in accordance with various embodiments. FIG. 9 is ablock diagram of two example grip trucks 800 of a dual ATP head ATPsystem during tape 101 laying in accordance with various embodiments.

With reference to FIGS. 1A-9 , the grip truck 800 may be similar to thelayup truck 100, except no tape 101 is fed through the grip truck 800.The grip truck 800 may be used to grip the composite surface. In thegrip truck 800 configuration, the grip truck rollers 103, 104 mayoperate as drive wheels whose purpose is to simultaneously press, hold,and translate the composite build. In the grip truck 800 configuration,the grip truck stanchions 110 may be attached to a common rotatablecollar 821 on a rotating link 820 forming a yoke and universal jointwhich may be mechanically controlled, such as by an actuator 811 asillustrated in FIG. 8B. Rotatable collar 821 is shown as rotating aroundthe Z-axis, with rollers 103, 104 rotating about the orthogonal Y-axis.The actuators 811 may be any type of actuators, such magneticallyoperated actuators (e.g., solenoids, etc.), electrically operatedactuators (e.g., piezoelectric stacks, electric motor driven ball screwactuators, etc.), hydraulic pump operated actuators (e.g., pistons,etc.), pressure pump operated actuators (e.g., pistons, diaphragms,etc.), and/or mechanical actuators (e.g., springs, etc.). The actuators811 may be controlled by a processor (or other type controller) of theATP head including the grip truck 800. The actuators 811 may rotate thegrip truck 800 about the Z axis in clockwise or counterclockwisedirections. The actuators 811 may shift the grip truck 800 back andforth along the Z axis. The actuators 811 may tilt the grip truck 800relative to the Y-axis in clockwise or counterclockwise directions.Rotation of the grip truck 800 about the Z-axis may change the axisaround which the grip truck 800 tilts.

In operation, the grip truck 800 may press against a similar opposinggrip truck 800 as illustrated in FIG. 9 , and the grip truck 800 gripsthe prepreg that has been deposited 108. Since the grip trucks 800 mayindependently rotate, tilt, and shift, the grip trucks 800 can hold thecomposite build as it curves, requires rotation, and/or changesthickness. While FIGS. 8A, 8B, and 9 illustrate the grip truck 800including twin rollers 103, 104, in alternative embodiments the griptruck 800 may include less rollers, such as only a single roller 103 or104, or may include more rollers such as additional rollers (e.g., suchthat the grip truck 800 include three, four, five, or more rollerssimilar to rollers 103 or 104).

FIG. 10 is a block diagram of components of an example dual ATP head ATPsystem 1000 illustrating tape 101 placement in accordance with variousembodiments. With reference to FIGS. 1A-10 , the dual ATP head ATPsystem 1000 may be similar to the ATP system 750 of FIG. 7B, except thatthe ATP heads may additionally include grip trucks 800. FIG. 10demonstrates the setup during the tape 101 laying in which the griptrucks 800 push opposite one another in addition to the oppositeinteracting layup trucks 100. The grip trucks 800 may be positioned oneither side of the ATP heads. The actuators 811 of the grip trucks 800may be connected to the controllers 707. The controllers 707 and/or thecomputing device 705 may control the operations of the grip trucks 800to independently rotate, tilt, and/or shift the grip trucks 800 to holdthe composite build.

In some embodiments, the truck system (e.g., a grouping of a layup truck100 and two grip trucks 800 discussed with reference to FIG. 10 as partof one of the ATP heads of the dual ATP head ATP system 1000) may becoupled together and encased with additional hardware, to create andadvanced applicator head system, or car as illustrated in FIG. 11 . Withreference to FIGS. 1A-11 , the car 1100 is a standalone ATP head thatcan connect to a robot arm or gantry (e.g., 702, 701) to build a complexcomposite with, or without, the use of a tool or frame. For example, thecar 1100 may be a specific example of an ATP head 706 that may be usedwith the ATP systems 700 and/or 750. The car 1100 may include a housing1102 encasing two grip trucks 800 and a layup truck 100. While two griptrucks 800 and a layup truck 100 are discussed as encased by the housing1102 of the car 1100, this is merely an example of the number of griptrucks 800 and/or layup trucks 100. Other configurations in accordancewith the various embodiments may include more than two grip trucks 800,such as three, four, five, six, more than six, etc., and/or more thanone layup truck 100, such as two, three, four, more than four, etc. Thehousing 1101 of the car 1100 may also encase other components of an ATPhead, such as the heat applicators 105, cutters 102, etc. While FIG. 11illustrates the tape reel 709 as disposed outside the housing 1101 ofthe car 1100, in an alternative configuration, the tape reel 709 mayalso be encased by the housing 1101.

In scenarios in which the car 1100 may be equipped with a positioningsystem or capability (e.g., position sensors providing position data toa controller, such as controller 707), the car 1100 may operateindependently as a self-contained system. For example, the car 1100 maybe the ATP head of an ATP system that does not require a robot arm organtry. Partial pressure may be applied to the prepreg by applying theweight of the car 1100 to each truck 100 and 800 and using theindependent truck control systems (e.g., the actuators 111 and/or 811controlled by the controller 707 and/or computing device 705) to affectthe locally applied loads. For example, the car 1100 may be controlledby the controller 707 and/or computing device 705. Specific examples ofchanging the applied pressure or load on the composite being made usingthe car (or cars) 1100 when the car (or cars) 1100 are used in an ATPsystem without a robot arm or gantry may include to add static weight(e.g., solid ingots, solid plates, etc.) and/or dynamic weight (e.g.,fluid to a bladder, etc.) to one of the cars 1100 (e.g., typically theupper car 1100) or by using electromagnets dynamically controlled toattract or repulse the other car 1100, accordingly. The computing device705 may be configured to control the operations of the controller 707,layup truck 100, grip trucks 800, actuators 111 and/or 811, and/orcomponents of the car 1100, such as the heat applicators 105, cutters102, tape reels 709, etc. As a specific example, the computing device705 may be configured to control the layup movements of the car 1100 andoperation of the layup truck 100, grip trucks 800, and/or actuators 111and/or 811 in accordance with various embodiments to bidirectionally laydown prepreg tape 101 to build a composite part. As a further specificexample, the computing device 705 may be configured to control the layupmovements of the car 1100 and operation of the layup truck 100, griptrucks 800, and/or actuators 111 and/or 811 in accordance with variousembodiments to bidirectionally lay down prepreg tape 101 to build acomposite part according to a lay down scheme, such as lay down scheme600. The lay down scheme, such as lay down scheme 600, may be configuredsuch that no head rotation of the car 1100 and/or diagonal headtranslation of the car 1100 may be required to build a composite part.

In scenarios in which two cars are used opposite of each other, and eachknows the position of the other's rollers 103, 104 (e.g., via positiontracking of the rollers 103, 104 and/or the actuators 111 and/or 811 bythe controller 707 and/or computing device 705), a composite panel maybe built with the bottom car 1100 (upside down and stationary) and thetopside car 1100 (right side up and stationary) by using the weight onthe rollers 103, 104 to shift the composite needed to build the part.This ability to shift the composite may be especially beneficial whenclosed shell tubular structure is needed, where a gantry or arm supportsystem prevents such a build without an internal mold or bladder. As aspecific example, the computing device 705 may be configured to controlthe layup trucks 100, grip trucks 800, and/or actuators 111 and/or 811of the cars 1100 and in accordance with various embodiments tobidirectionally lay down prepreg tape 101 to build a composite partwithout the cars 1100 moving (i.e., the car 1100 remain stationary andthe control of the layup trucks 100, grip trucks 800, and/or actuators111 and/or 811 of the cars 1100 moves the part being built-up). As afurther specific example, the computing device 705 may be configured tocontrol the layup trucks 100, grip trucks 800, and/or actuators 111and/or 811 of the cars 1100 in accordance with various embodiments tobidirectionally lay down prepreg tape 101 to build a composite partaccording to a lay down scheme in which the cars 1100 remain stationaryand the activations of the layup trucks 100, grip trucks 800, and/oractuators 111 and/or 811 of the cars 1100 cause the part being built-upto move. The lay down scheme may be configured such that no positionchange of the cars 1100 may be required to build a composite part (i.e.,such that the top car 1100 and the bottom car 1100 remain stationary andthe composite part moves).

In some embodiments, in scenarios in which the composite structure lacksinitial stiffness, a system of actuated ball posts 1202 may be used toassist in helping the composite maintain its shape during themanufacturing process. With reference to FIGS. 1-12 , FIG. 12 is a blockdiagram of a portion of an example ATP system during tape 101 lay downin accordance with various embodiments in which actuated ball posts 1202support the part being formed. Two cars 1100 may lay down tape 101 andmove the composite part being fabricated over the posts 1202. The cars1100 may remain stationary and the part may translate relative to thecars 1100 over the posts 1202. The height of the posts 1202 may bemonitored and controlled by a computing device connected to the posts1202, such as computing device 705. FIG. 12 shows an upside-down car1100 with the required top car not shown for ease of illustration in aneffort to demonstrate how the adjustable ball posts 1202 support aflexible composite being fabricated. The capped balls of the posts 1202allow the panel of laid down tape 108 to slide in any directiondetermined by the car's 1100 trucks. Additionally, the adjustable heightof the posts 1202 may accommodate curved shells.

The various embodiments described above may also be implemented within avariety of computing devices, such as a laptop computer 1300 illustratedin FIG. 13 . For example, the laptop computer 1300 may be an example ofcomputing device 705. Many laptop computers include a touchpad 1317 withtouch surface that serves as the computer's pointing device, and thusmay receive drag, scroll, and flick gestures similar to thoseimplemented on mobile computing devices equipped with a touch screendisplay and described above. A laptop computer 1300 will typicallyinclude a processor 1311 coupled to volatile memory 1312 and a largecapacity nonvolatile memory, such as a disk drive 1313 of Flash memory.Additionally, the laptop computer 1300 may have one or more antennas1308 for sending and receiving electromagnetic radiation that may beconnected to a wireless data link and/or cellular telephone transceiver1316 coupled to the processor 1311. The laptop computer 1300 may alsoinclude a floppy disc drive 1314 and a compact disc (CD) drive 1315coupled to the processor 1311. In a notebook configuration, the computerhousing includes the touchpad 1317, the keyboard 1318, and the display1319 all coupled to the processor 1311. Other configurations of themobile computing device may include a computer mouse or trackballcoupled to the processor (e.g., via a USB input) as are well known,which may also be used in conjunction with the various embodiments.

The processors described herein may be any programmable microprocessor,microcomputer or multiple processor chip or chips that can be configuredby software instructions (applications) to perform a variety offunctions, including the functions of the various embodiments describedabove. In some embodiments, multiple processors may be provided, such asone processor dedicated to wireless communication functions and oneprocessor dedicated to running other applications. Typically, softwareapplications may be stored in the internal memory before they areaccessed and loaded into the processor. The processor may includeinternal memory sufficient to store the application softwareinstructions. In many devices, the internal memory may be a volatile ornonvolatile memory, such as flash memory, or a mixture of both. For thepurposes of this description, a general reference to memory refers tomemory accessible by the processors including internal memory orremovable memory plugged into the device and memory within theprocessors itself.

The foregoing method descriptions and the process flow diagrams areprovided merely as illustrative examples and are not intended to requireor imply that the steps of the various embodiments must be performed inthe order presented. As will be appreciated by one of skill in the artthe order of steps in the foregoing embodiments may be performed in anyorder. Words such as “thereafter,” “then,” “next,” etc. are not intendedto limit the order of the steps; these words are simply used to guidethe reader through the description of the methods. Further, anyreference to claim elements in the singular, for example, using thearticles “a,” “an” or “the” is not to be construed as limiting theelement to the singular.

The various illustrative logical blocks, modules, circuits, andalgorithm steps described in connection with the embodiments disclosedherein may be implemented as electronic hardware, computer software, orcombinations of both. To clearly illustrate this interchangeability ofhardware and software, various illustrative components, blocks, modules,circuits, and steps have been described above generally in terms oftheir functionality. Whether such functionality is implemented ashardware or software depends upon the particular application and designconstraints imposed on the overall system. Skilled artisans mayimplement the described functionality in varying ways for eachparticular application, but such implementation decisions should not beinterpreted as causing a departure from the scope of the presentinvention.

The hardware used to implement the various illustrative logics, logicalblocks, modules, and circuits described in connection with the aspectsdisclosed herein may be implemented or performed with a general purposeprocessor, a digital signal processor (DSP), an application specificintegrated circuit (ASIC), a field programmable gate array (FPGA) orother programmable logic device, discrete gate or transistor logic,discrete hardware components, or any combination thereof designed toperform the functions described herein. A general-purpose processor maybe a microprocessor, but, in the alternative, the processor may be anyconventional processor, controller, microcontroller, or state machine. Aprocessor may also be implemented as a combination of computing devices,e.g., a combination of a DSP and a microprocessor, a plurality ofmicroprocessors, one or more microprocessors in conjunction with a DSPcore, or any other such configuration. Alternatively, some steps ormethods may be performed by circuitry that is specific to a givenfunction.

In one or more exemplary aspects, the functions described may beimplemented in hardware, software, firmware, or any combination thereof.If implemented in software, the functions may be stored as one or moreinstructions or code on a non-transitory computer-readable medium ornon-transitory processor-readable medium. The steps of a method oralgorithm disclosed herein may be embodied in a processor-executablesoftware module and/or processor-executable instructions, which mayreside on a non-transitory computer-readable or non-transitoryprocessor-readable storage medium. Non-transitory server-readable,computer-readable or processor-readable storage media may be any storagemedia that may be accessed by a computer or a processor. By way ofexample but not limitation, such non-transitory server-readable,computer-readable or processor-readable media may include RAM, ROM,EEPROM, FLASH memory, CD-ROM or other optical disk storage, magneticdisk storage or other magnetic storage devices, or any other medium thatmay be used to store desired program code in the form of instructions ordata structures and that may be accessed by a computer. Disk and disc,as used herein, includes compact disc (CD), laser disc, optical disc,DVD, floppy disk, and Blu-ray disc where disks usually reproduce datamagnetically, while discs reproduce data optically with lasers.Combinations of the above are also included within the scope ofnon-transitory server-readable, computer-readable and processor-readablemedia. Additionally, the operations of a method or algorithm may resideas one or any combination or set of codes and/or instructions on anon-transitory server-readable, processor-readable medium and/orcomputer-readable medium, which may be incorporated into a computerprogram product.

The preceding description of the disclosed embodiments is provided toenable any person skilled in the art to make or use the presentinvention. Various modifications to these embodiments will be readilyapparent to those skilled in the art, and the generic principles definedherein may be applied to other embodiments without departing from thespirit or scope of the invention. Thus, the present invention is notintended to be limited to the embodiments shown herein but is to beaccorded the widest scope consistent with the following claims and theprinciples and novel features disclosed herein

1. An Automated Tape Placement (ATP) head for deposition of a prepregtape, comprising: a layup truck, comprising: at least one stanchion; tworollers; a rotating transmission pivotally mounted to the at least onestanchion, the transmission having at least two support arms rotatablysupporting the two rollers so that the two rollers are configured torotate about a first axis, wherein: the rotating transmission isconfigured to tilt about the first axis relative to the at least onestanchion, with a first of the at least two support arms moving awayalong a second axis from tape deposition, the second axis orthogonal tothe first axis, and a second of the at least two support arms movingalong the second axis toward tape deposition, such that in a firstposition of the rotating transmission a first of the two rollersoperates as a compaction drive wheel and the second of the two rollersoperates as a tensioning guide drive wheel for a tape being deposited bythe ATP head and in a second position of the rotating transmission, thesecond of the at least two support arms is moving away along a secondaxis from tape deposition and the first of the at least two support armsmoving along the second axis toward tape deposition, the second of thetwo rollers operates as the compaction drive wheel and the first of thetwo rollers operates as the tensioning guide drive wheel for the tapebeing deposited by the ATP head; the tape being deposited by the ATPhead passes between the two rollers; the tape being deposited by the ATPhead contacts both of the two rollers in both of the first position ofthe rotating transmission and the second position of the rotatingtransmission; and wherein, as the transmission tilts the two rollersrotate about each other in a plane defined by the first and second axesso that the two rollers are in engagement with the tape facilitating achange in laydown direction while maintaining tension on the tape. 2.The ATP head of claim 1, further comprising: at least one actuatorcoupled to the layup truck, wherein the at least one actuator isconfigured to move the layup truck toward the tape being deposited bythe ATP head such that the first or the second roller operating as thecompaction drive wheel compacts the tape onto a working surface.
 3. TheATP head of claim 1, wherein the two rollers are in constant engagementwith the tape facilitating a change in laydown direction whilemaintaining substantially consistent tension on the tape.
 4. The ATPhead of claim 1 further comprising: at least one grip truck, comprising;two grip truck rollers; a grip truck rotating transmission supportingthe two grip truck rollers; grip truck stanchions supporting the griptruck rotating transmission; and a rotatable collar attached to the griptruck stanchions and including a rotating link, where the tape beingdeposited buy the ATP head does not pass between the two grip truckrollers of the at least one grip truck.
 5. An ATP system for depositionof a prepreg first tape, comprising: a first ATP head, comprising: afirst layup truck, comprising: at least one stanchion; two rollers; arotating transmission pivotally mounted to the at least one stanchion,the transmission having at least two support arms rotatably supportingthe two rollers so that the two rollers are configured to rotate about afirst axis, wherein the rotating transmission is configured to tiltabout the first axis relative to the at least one stanchion, with thefirst of the at least two support arms moving away along a second axisfrom tape deposition, the second axis orthogonal to the first axis, anda second of the at least two support arms moving along the second axistoward tape deposition, such that in a first position of the rotatingtransmission a first of the two rollers operates as a compaction drivewheel and the second of the two rollers operates as a tensioning guidedrive wheel for a first tape being deposited by the first ATP head andin a second position of the rotating transmission, the second of the atleast two support arms is moving away along a second ais from tapedeposition and the first of the at least two support arms moving alongthe second axis toward tape deposition, the second of the two rollersoperates as the compaction drive wheel and the first of the two rollersoperates as the tensioning guide drive wheel for the first tape beingdeposited by the first ATP head; the first tape being deposited by thefirst ATP head passes between the two rollers; and the first tape beingdeposited by the first ATP head contacts both of the two rollers in bothof the first position of the rotating transmission and the secondposition of the rotating transmission; and wherein as the transmissiontilts the two rollers rotate about each other in a plane defined by thefirst and second axes so that the two rollers are in engagement with thetape facilitating a change in laydown direction while maintainingtension on the tape.
 6. The ATP system of claim 5, wherein the first ATPhead further comprises: at least one actuator coupled to the layuptruck, wherein the at least one actuator is configured to move the layuptruck toward the first tape being deposited by the first ATP head suchthat the first or the second roller operating as the compaction drivewheel compacts the first tape onto a working surface.
 7. The ATP systemof claim 6, further comprising: a second ATP head, wherein the workingsurface is a second tape being deposited by the second ATP head.